Specialized packaging

ABSTRACT

The present invention comprises an outer box comprising four sidewalls, a first end and a second end; a rat box comprising a crush zone, the rate box positioned at at least one end of the outer box; a half moon support fitting against the walls of the outer box comprising a surface in contact with a product surface and angled slots diverging interiorly from an outer edge of the half moon support; torpedo shield panels positioned inside of the outer box having a center panel and two side panels diverging at an angle with respect to the center panel, the side panels at least partially fitting into the slots of the half moon support; and an inner support having a plurality of contact points for contacting an inner product surface, the inner support extending beyond each end of the product and received by the rat box, thereby suspending the product within the outer box.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Application No. 61/093,714 filed Sep. 2, 2008.

FIELD OF THE INVENTION

This invention relates generally to novel packaging for shipped objects and more particularly to packaging for chimney pipe.

BACKGROUND OF THE INVENTION

Manufactured products are generally shipped or mailed to their final destination. One such product is chimney pipe. In many applications, chimney pipe is installed outside and visible to the public. As such, modern chimney pipes are plated or coated to make them aesthetically pleasing.

It is not uncommon for chimney pipe to be scratched, dented or otherwise damaged during shipping, requiring the installer to ship the item back for replacement. This can cause project delays with resultant cost overruns, wasted time, effort and resources.

Known packaging uses rectangular boxes in which the chimney pipe is placed. There may or may not be padding surrounding the chimney pipe. Most often the packaging is in direct contact with the pipe with no crush zones so that, for example, if a pointed object pierces the box, the chimney pipe is easily scratched or dented.

Formed plastic has been used to encase and protect shipped items. However, this packaging method greatly the increases the packaging costs, is not environmentally sound, and is too expensive to be cost effective for lower priced items such as chimney pipe.

Accordingly, there is still a continuing need for an economical, light weight, environmentally-friendly packaging which more effectively protects shipped products than does known packaging. The present invention fulfills this need and further provides related advantages.

BRIEF SUMMARY OF THE INVENTION

The present invention provides an improved package design for protecting a product during shipment.

In a first embodiment, the present invention comprises:

-   a) an outer box comprising four sidewalls, a first end and a second     end; -   b) a rat box comprising a crush zone, the rate box positioned at at     least one end of the outer box; -   c) a half moon support fitting against the inner wall of the outer     box comprising a surface in contact with a product surface and     angled slots diverging interiorly from an outer edge of the half     moon support; -   d) torpedo shield panels positioned inside of the outer box having a     center panel and two side panels diverging at an angle with respect     to the center panel, the side panels at least partially fitting into     the slots of the half moon support; and -   e) an inner support having a plurality of contact points for     contacting an inner product surface, the inner support extending     beyond each end of the product and received by the rat box, thereby     suspending the product within the outer box.

In a second embodiment, the at least one half moon support and the torpedo shields are omitted.

It is an object of the present invention to provide packaging which protects shipped products from scratches.

It is an object of the present invention to provide packaging which protects shipped products from dents.

It is an object of the present invention to provide protective packaging which is economical.

It is an object of the present invention to provide protective packaging which is environmentally-friendly.

It is an object of the present invention to provide protective packaging which has reduced waste.

It is an object of the present invention to provide protective packaging which is light weight.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the present invention. These drawings are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the present invention, and together with the description, serve to explain the principles of the present invention.

FIG. 1 is a perspective view of the novel packaging according to the present invention.

FIG. 2 is a side elevational view of the novel packaging according to the present invention.

FIG. 3 is a cross-sectional plan view of the novel packaging according to the present invention shown in FIG. 2.

FIG. 4 is a plan view of the cardboard cut outs which are folded into a rat box of the packaging according to a first embodiment of the present invention.

FIG. 5 is a plan view of the cardboard cut outs which are folded into the inner support of the packaging according to the present invention.

FIG. 6 is a plan view of the cardboard cut outs which are folded into the torpedo shield of the novel packaging according to the present invention.

FIG. 7 is a cut out of several half moon supports.

FIG. 8 shows a cross sectional view of a support according to the prior art.

FIG. 9 shows a cross sectional view of a half moon support interlocked with the torpedo shield.

FIG. 10 is a plan view of the cardboard cut outs which are folded into a rat box of the packaging according to a second embodiment of the present invention.

FIG. 11 is a cross-sectional plan view of the novel packaging according to a second embodiment of the present invention.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

DETAILED DESCRIPTION OF THE INVENTION

As required, detailed embodiments of the present invention are disclosed; however, it should be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. The figures are not necessary to scale, and some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.

In the following exemplars, the present invention is fabricated of cardboard. Cardboard is economical, rigid, lightweight, offers protection against scratching and denting and is environmentally-friendly. However, the invention is not limited to cardboard.

Turning now to the Figures, FIG. 1 is a perspective view of the novel packaging according to a first embodiment of the present invention. An outer box 1100 shown with its front face removed, encloses a product 1 being shipped. In this embodiment, product 1 has an elongated cylinder shape, for example, a chimney pipe. However, the packaging is not limited to an elongated cylinder shape and may be used with slight modifications to package objects having various shapes and cross sections.

An elongated package, such as packaging used to ship chimney pipe, is most prone to damage when it falls on an end, due to the substantial force concentrated on a relatively small surface area. To protect the ends of the product 1, a ‘rat box’ 1200 is constructed and used at either end of the package 1000, each rat box 1200 having end crush zones 1210.

Two half moon supports 1500 hold product 1 in the center of the box 1100. Each half moon support 1500 includes a product interface surface shaped to mate with the product 1. Each half moon support 1500 has a corresponding half moon support 1500 on the opposite side of the product 1 thereby creating support around the perimeter of the product 1.

Each half moon support 1500 has an angled slot 1510 which receives an edge of a torpedo shield 1400. Torpedo shields 1400 are shown in phantom for clarity. There are torpedo shields 1400 on opposite sides of product 1. These torpedo shields 1400 are designed to provide additional protection to the product 1 should an object break the integrity of outer box 1100. The elongated torpedo shield 1400 fits within the angled slots 1510 of the half moon supports 1500.

Preferably, each torpedo shield 1400 is comprised of a single piece having a center panel and two side panels diverging at an angle with respect to the center panel, the side panels at least partially fitting into the slots 1510 of the half moon support 1500. The geometry of the torpedo shield 1400 serves to transfer/redirect an impact force away from the product 1 into the half moon support 1500. This transfer/redirection of impact force is novel from the prior art which uses geometry that serves only to act as a physical block to an impact. Without the novel force redirection capability of the present invention, the prior art can suffer deformation of the product when receiving an impact, even if the prior art geometry prevents direct impact contact to the product.

FIG. 2 is a side elevational view of the novel packaging according to the present invention. In this view, outer box 1100 is shown enclosing product 1. Rat boxes 1200 containing crush zones 1210 are shown at either end of package 1000. The two half moon supports 1500 are shown in cross section. Rigidity is achieved by, for example, several folded cardboard layers. Torpedo shield 1400 is shown in phantom for clarity. The torpedo shield on the opposite side of product 1 is not visible from this view.

FIG. 3 is a cross-sectional plan view of the novel packaging according to the present invention shown in FIG. 2.

Viewing FIGS. 2 and 3, the outer box 1100 is visible enclosing shipped product 1. The rat box 1200 is shown at either end of the package 1000 each having end crush zones 1210. The two half moon supports 1500 have a product interface surface shaped to hold product 1 in the center of the box 1100. A torpedo shield 1400 is shown in phantom (FIG. 2) over product 1. The elongated torpedo shield 1400 fits within the half moon support 1500.

It is possible that an impact striking at an angle to the end of package 1000 could collapse the ends of a hollow product 1, for example, a chimney pipe. In order to protect such hollow products 1, an inner support 1600 is provided. Inner support 1600 has, for example a triangular cross sectional shape which fits snugly inside of the open ends of product 1. Optionally, other cross sectional shapes that provide interior support to a hollow product may be used, for example, an octagonal cross sectional shape or any other geometric cross sectional shape that provides supporting contact points within the product 1.

Although inner support 1600 may span the entire length of product 1, in a preferred embodiment, inner support 1600 comprises two separate end pieces. Regardless of whether inner support comprises two separate pieces or a single piece, inner support 1600 extends beyond the product 1 to engage a mating cutout in the rat boxes 1200. In this manner, product 1 is suspended within package 1000.

FIG. 4 is a plan view of a cardboard cut-out pattern which is folded into a rat box 1200 of the novel packaging according to the present invention. The mating cutout, for example, triangular cut out 1211 in panel 1201, 1213 in panel 1203, 1251 in panel 1231 and 1253 in panel 1233 is provided. A panel 1202 connects panels 1201 and 1203. Similarly, a panel 1232 connects panels 1231 and 1233.

Fold lines 1271, 1273 and 1275, 1279 indicate where panels 1201 and 1203 fold over each other making a box shape with the triangular cut outs 1211 and 1213 overlapping each other to make a single triangular hole.

A portion 1285 between fold lines 1271 and 1273 becomes a side of the folded rat box 1200. Similarly, a portion 1287 between fold lines 1275, 1279 becomes the other side of rat box 1200. Notches 1281 overlap notches 1283 of panels 1202 and 1232 to create a recess to receive the top and bottom edges of torpedo shields 1400. Tabs 1260 fold to make the other sides of the rat box 1200. Rat box 1200 is now ready to receive and hold the inner support 1600.

FIG. 5 is a plan view of the cardboard cut-out which folds into the exemplar triangular shaped inner support 1600 of the novel packaging according to the present invention.

Surface 1610 is one of the faces of the inner support 1600. By folding on the fold lines 1651, 1610 becomes one of the triangular faces, panels 1620 become two of the other faces. Sections 1640 allow space for folding and provide a flattened apex of the triangular shape. Panels 1630 overlap each other.

FIG. 6 is a plan view of the cardboard cut outs which are folded into the torpedo shield 1400 of the novel packaging according to the present invention. By folding torpedo shield 1400 cut out on center line 1423, a double layer thickness with panels 1410 overlapping each other is formed. Panels 1420 each overlap as do panels 1430. Notches 1433 overlap notches 1431 on one side and notches 1421 on the other side. These notches fit into slots 1510 of half moon support 1500 shown in FIG. 7. By partially folding panels 1420 and 1430, the torpedo shield 1400 takes on its characteristic shape as shown in FIG. 1.

Panels 1430 are partially folded on line 1411. Panels 1420 are also partially folded at line 1413 to create the characteristic shape of torpedo shield 1400. The upper and lower corners of the partially folded torpedo shield 1400 fit into the recesses created from notches 1281 and 1283 of FIG. 4.

FIG. 7 is a cut out of several half moon supports 1500. The cutout is cut on line 1515 to result in two identical mirror images. Each is folded into a half-moon support 1500.

For ease of reading, only one panel side 1520 of the cut out is described. Other sides are similarly formed. Panels 1517, 1519, 1521 and 1523 are connected to each other at fold lines 1511. Depending upon the thickness of the materials used and the desired strength, the left set of panels 1520 may be folded into 1, 2 or 4 half moon supports 1500. Panels 1517 may be folded onto panel 1519. They may additionally be folded onto panels 1521 and 1523.

The panels are scored, or partially cut on line 1513 to allow easier folding. The panels are then folded on line 1513 to create the half moon shape. The inner surface 1517 is designed to fit against and support the product 1 (FIG. 1). Optionally this inner surface may be covered with a material to further prevent scratching of the product.

In this manner, the structure of the half moon supports 1500 and the torpedo shield 1400 fit together to make a structure which surrounds the product 1 perimeter, holds itself together without connectors, is rigid, and resists torsional forces. Due to the geometry of the half moon supports 1500, the angled slots 1510 and the torpedo shield 1400, a rigid structure is formed.

FIG. 8 shows a cross sectional view of a support according to the prior art. A flat elongated piece 11 is shown with it folded at 90 degree angles to create side panels 13. The slots 15 are perpendicular to the front edge 17 allowing the side panels 13 to slide into them. This allows for easy construction. Problematically, the side panels 13 slide out just as easily as they slide into slots 15.

Twisting elongated piece 11 causes the left edge 13 to move in the direction of arrow A into slot 15. If left side panel 13 is fully inserted into slot 15, then it does not move. However, the right edge panel 13 is forced to move in the direction marked by arrow B out of slot 15 causing it to partially disassemble. With the prior art design, if a force contacts elongated piece 11 in a direction marked by arrow “C”, the entire elongated piece 11 may be pulled out of slots 15. These may progressively ‘creep’; moving further and further out until it is disassembled. Furthermore, as discussed above, the prior art does not allow for transfer/redirection of the impact force away from the product.

FIG. 9 shows a cross sectional view of a half moon support 1500 interlocked with the torpedo shield 1400. Due to the geometry of the present device, it is harder to disassemble. Center panel 1410 must be bowed to allow side panels 1420, 1430 to be inserted into slots 1510. However, when a force is applied in the direction marked by arrow “D”, side panels 1420, 1430 resist being pulled out of slots 1510 and return to their original positions after the force is removed. This geometry only disassembles when force D is great enough to pull side panel 1430 entirely out of slots 1510. In this manner, the present invention employs a more rigid internal structure, which is more resilient and better protects the product than does the prior art.

The above embodiment of the present invention is envisioned for use with spans of product 1, where without such rigidity, package 1000 could fold upon receiving a side impact thereby causing damage to product 1.

When shorter spans of product 1 are packaged, for example, spans of about twenty four inches or less, the added rigidity provided by half moon supports 1500 and torpedo shields 1400 become optional. Packages 1000 of such lengths have been found to be sufficiently rigid so a to not fold during a side impact. However, to better protect such shorter spans of product 1, when half moon supports 1500 and torpedo shield 1400 are omitted, inner support 2600 (FIG. 11) ideally comprises more contact points than a triangular cross-sectional geometric shape provides. Preferably, an octagonal cross-sectional geometric shape is utilized, although inner support 2600 is not limited to an octagonal cross-sectional geometric shape.

FIG. 10 is a plan view of a cardboard cut-out pattern which is folded into a rat box 1200 of the novel packaging according to a second embodiment. The mating cutout, for example, octagonal cut out 2211 in panel 2201 and 2213 in panel 2203 is provided. A panel 2202 connects panels 2201 and 2203.

Fold lines 2271, 2273 and 2275, 2279 indicate where panels 2201 and 2203 fold over each other making a box shape with the octagonal cut outs 2211 and 2213 overlapping each other to make a single octagonal hole.

A portion 2285 between fold lines 2271 and 2273 becomes a side of the folded rat box 1200. Similarly, a portion 2287 between fold lines 2275, 2279 becomes the other side of rat box 1200. Notches 2281 overlap notches 2283 of panel 2202 to create a recess to receive the top and bottom edges of optional torpedo shields 1400, should they be utilized. Tabs 2260 fold to make the other sides of the rat box 1200. Rat box 1200 is now ready to receive and hold the inner support 2600.

FIG. 11 is a cross-sectional plan view according to the second embodiment. The optional two half moon supports 2500 have a product interface surface shaped to hold product 1 in the center of the box. An optional torpedo shield 2400 is shown over product 1. The optional elongated torpedo shield 2400 fits within the optional half moon support 2500, received by slots 2510 of optional half moon support 2500. Inner support 2600 fits snugly inside of the open ends of product 1.

Although the present invention has been described in connection with specific examples and embodiments, those skilled in the art will recognize that the present invention is capable of other variations and modifications within its scope. These examples and embodiments are intended as typical of, rather than in any way limiting on, the scope of the present invention as presented in the appended claims. 

1. A protective packaging for a product comprising: a) an outer box comprising four sidewalls, a first end and a second end; b) a rat box comprising a crush zone, the rat box positioned at at least one end of the outer box; c) a half moon support fitting against a sidewall of the outer box comprising a surface in contact with a product surface and angled slots diverging interiorly from an outer edge of the half moon support; d) a torpedo shield positioned inside of the outer box having a center panel and two side panels diverging at an angle with respect to the center panel, the side panels at least partially fitting into the slots of the half moon support so as to redirect an impact force away from the product; and e) an inner support having a plurality of contact points for contacting an inner product surface, the inner support extending beyond each end of the product and received by the rat box, thereby suspending the product within the outer box.
 2. The protective packaging of claim 1 further comprising two half moon supports and two torpedo shields, each being a mirror image of one another.
 3. The protective packaging of claim 1 wherein the inner support has a triangular cross sectional geometric shape.
 4. The protective packaging of claim 1 wherein the inner support has an octagonal cross sectional geometric shape.
 5. The protective packaging of claim 1 wherein the inner support comprises a single structure spanning the length of and extending beyond the end of the product.
 6. The protective packaging of claim 1 wherein the inner support comprises two structures positioned at and extending beyond each of the first end and the second end.
 7. The protective packaging of claim 1 wherein the first end and the second end each comprise a rat box.
 8. The protective packaging of claim 1 wherein the rat box comprises an orifice having a cross sectional geometric shape mirroring that of the inner support and sized to receive the inner support.
 9. A protective packaging for a product comprising: a) an outer box comprising four sidewalls, a first end and a second end; b) a rat box comprising a crush zone, the rat box positioned at at least one end of the outer box; and c) an inner support having a plurality of contact points for contacting an inner product surface, the inner support extending beyond each end of the product and received by the rat box, thereby suspending the product within the outer box.
 10. The protective packaging of claim 9 wherein the inner support has a triangular cross sectional geometric shape.
 11. The protective packaging of claim 9 wherein the inner support has an octagonal cross sectional geometric shape.
 12. The protective packaging of claim 9 wherein the inner support comprises a single structure spanning the length of and extending beyond the end of the product.
 13. The protective packaging of claim 9 wherein the inner support comprises two structures positioned at and extending beyond each of the first end and the second end.
 14. The protective packaging of claim 9 wherein the first end and the second end each comprise a rat box.
 15. The protective packaging of claim 9 wherein the rat box comprises an orifice having a cross sectional geometric shape mirroring that of the inner support and sized to receive the inner support.
 16. A method for packaging a product for shipment comprising the steps of: a. placing an inner support within the product; and b. placing the inner support and product within an outer box; wherein the outer box comprises four sidewalls, a first end and a second end; a rat box comprising a crush zone is positioned at at least one end of the outer box; and the inner support comprises a plurality of contact points for contacting an inner product surface, the inner support extending beyond each end of the product and received by the rat box, thereby suspending the product within the outer box.
 17. The method of claim 16 further comprising: a half moon support fit against a sidewall of the outer box, the half moon support comprising a surface in contact with an outer product surface and angled slots diverging interiorly from an outer edge of the half moon support; and a torpedo shield positioned inside of the outer box having a center panel and two side panels diverging at an angle with respect to the center panel, the side panels at least partially fitting into the slots of the half moon support so as to redirect an impact force away from the product.
 18. The method of claim 17 further comprising two half moon supports and two torpedo shields, each being a mirror image of one another.
 19. The method of claim 16 wherein the inner support has a triangular cross sectional geometric shape.
 20. The method of claim 17 wherein the inner support has an octagonal cross sectional geometric shape.
 21. The method of claim 17 wherein the inner support comprises a single structure spanning the length of and extending beyond the end of the product.
 22. The method of claim 17 wherein the inner support comprises two structures positioned at and extending beyond each of the first end and the second end.
 23. The method of claim 17 wherein the rat box comprises an orifice having a cross sectional geometric shape mirroring that of the inner support and sized to receive the inner support. 